Pigmented size press and surface size for coated paper and paperboard

ABSTRACT

A size press composition for paper or paperboard is provided, which includes:
         binder;   pigment;   synthetic surface sizing agent; and   water;   wherein the binder and pigment are present in a binder:pigment weight ratio of about 10:1 to about 1:10; and   wherein the synthetic surface sizing is present in a synthetic surface sizing agent:(binder and pigment) weight ratio of about 2:100 to about 10:100.

BACKGROUND

The present inventor has observed that in papermaking, one normally seesa lot of dewatering of the coating at the first coating station. This ismore pronounced as the paper/paperboard basis weight increases, as morefibers are available to absorb the water out of the coating. This cancause loss of coating binder into the sheet with the water, so thathigher latex levels are required to compensate for this loss. This canalso cause premature immobilization of the coating solids, which makesit difficult to control the coatweight at the blade coater. Thedewatering also limits the solids content of the coating that can beused. The inventor has found that it is possible to increase the solidscontent of the coatings used at both coating heads. Increased solidscontent of the coatings means that less water is present for a givencoatweight, so higher machine speeds are possible if the machine speedis limited by drying capability of the paper machine. Paperboard canalso be rougher than a lightweight paper, especially as the thickness ofthe paperboard increases.

Synthetic surface sizing agents, such as styrene acrylic emulsions(SAE), ScripSet™ styrene maleic anhydride (SMA), or alkyl ketene dimer(AKD) are commonly used to improve printability of the paper surface.These synthetic surface sizing agents can improve toner adhesion forelectrophotographic printing, and reduce ink bleed for ink jet andflexographic printing.

Starch/GCC mixtures have been used at the size press to make pigmentedpaper for premium ink jet and laser paper. These papers are uncoated,and are not subsequently coated, but are pigmented at the size press asa replacement for coated paper.

The inventor has found that it is possible to modify the size pressformulation to create a water barrier layer to decrease or prevent thedewatering of the coating, and also to fill in the pores at the papersurface. The inventor has found that, surprisingly, both of these willhelp keep the coating pigments and binder, for example a latex binder,at the paper surface. This will also make the sheet smoother so thatless coating is needed to attain a given smoothness.

BRIEF DESCRIPTION OF THE SEVERAL EMBODIMENTS

One embodiment provides a size press composition for paper orpaperboard, comprising:

binder;

pigment;

synthetic surface sizing agent; and

water;

wherein the binder and pigment are present in a binder:pigment weightratio of about 10:1 to about 1:10; and

wherein the synthetic surface sizing is present in a synthetic surfacesizing agent:(binder and pigment) weight ratio of about 2:100 to about10:100.

Another embodiment provides a sized web, for paper or paperboard,comprising:

a dried web comprising cellulosic fibers; and

the size press composition on one or both sides of the dried web.

Another embodiment provides a coated or uncoated paper or paperboard,comprising the sized web.

Another embodiment provides a paper or paperboard, comprising:

a sized web, comprising:

-   -   a dried web comprising cellulosic fibers; and    -   a size press composition on one or both sides of the dried web,        the size press composition comprising:        -   binder;        -   pigment;        -   synthetic surface sizing agent; and        -   substantially no water;

wherein the binder and pigment are present in a binder:pigment weightratio of about 10:1 to about 1:10; and

wherein the synthetic surface sizing is present in a synthetic surfacesizing agent:(binder and pigment) weight ratio of about 2:100 to about10:100.

Another embodiment provides an article, comprising the paper orpaperboard.

Another embodiment provides a method, comprising contacting, on apapermaking machine:

a dried web comprising cellulosic fibers; and

the size press composition;

to form a sized web.

DETAILED DESCRIPTION OF THE SEVERAL EMBODIMENTS

In one embodiment, a size press composition for paper or paperboard isprovided, which includes:

binder;

pigment;

synthetic surface sizing agent; and

water;

wherein the binder and pigment are present in a binder:pigment weightratio of about 10:1 to about 1:10; and

wherein the synthetic surface sizing is present in a synthetic surfacesizing agent:(binder and pigment) weight ratio of about 2:100 to about10:100.

In embodiments herein, the size press composition may be in the form ofan aqueous solution, slurry, emulsion, dispersion, suspension, mixture,thixotropic composition, or colloidal composition.

In embodiments herein, the binder may include one or more of naturalproduct, casein, soy protein, fatty acid salts and copolymers, watersoluble polymer, water soluble starch co-binder, polyvinyl alcohol, polyacrylic acid, poly acrylic acid salt, polyvinylpyrrolidone, polyethyleneglycol, polyethylene oxide, polymer emulsion, acrylate, styreneacrylate, styrene butadiene, styrene acrylonitrile, polyurethane,polyvinyl acetate, polyethylene emulsion, polyethylene (PE) polymers;polyethylene terephthalate (PET) polymers; polyhydroxyalkanoate (PHA)polymers; polylactic acid (PLA) polymers; polyglycolic acid (PGA)polymers; polyvinyl acetate polymers; waxes; polyurethane polymers; orepoxy resins, starch, high-amylose corn starch, waxy corn starch,tapioca starch, cationic starch, ethylated starch, oxidized starch, cornstarch, potato starch, rice starch, dent corn starch, waxy starch,modified starch, FilmKote™ by Ingredion, FilmKote 370™ by Ingredion(modified starch), Aquabloc™ by Aquasol, Aquabloc 403™ by Aquasol(starch), Flex Starch™ by Tate and Lyle, Clear-Cote 640™ by Tate andLyle (waxy starch), PG270™ by Ingredion (ethylated starch), RAP 810™ byTrinseo (styrene acrylate), XU 31669 SB™ latex by Trinseo (styrenebutadiene), XU 31695™ by Trinseo (styrene acrylonitrile), Polyco 3960™by Dow (poly vinyl acetate), Polyco 2160 IPA™ by Dow (poly vinylacetate), binder, Hypod 1001™ by Dow (polyethylene emulsion), Hypod9105™ by Dow (polyethylene emulsion), or a combination thereof.

In embodiments herein, the binder may include one or more naturalproducts such as casein, soy protein, and fatty acid salts andcopolymers, water soluble polymers such as polyvinyl alcohol, polyacrylic acid and salts, polyvinylpyrrolidone, polyethylene glycol,polyethylene oxide, etc, and polymer emulsions such as acrylates,styrene acrylates, styrene butadienes, polyurethanes, polyvinylacetates, polyethylene (PE) polymers; polyethylene terephthalate (PET)polymers; polyhydroxyalkanoate (PHA) polymers; polylactic acid (PLA)polymers; polyglycolic acid (PGA) polymers; polyvinyl acetate polymers;waxes; polyurethane polymers; or epoxy resins, and their copolymers andderivatives. Any combination thereof may be suitably used.

In embodiments herein, the binder may include a starch selected from thegroup including high-amylose corn starch, waxy corn starch, tapiocastarch, cationic starch, ethylated starch, oxidized starch, corn starch,potato starch, rice starch, dent corn starch, waxy starch, modifiedstarch, FilmKote™ by Ingredion, FilmKote 370™ by Ingredion (modifiedstarch), Aquabloc™ by Aquasol, Aquabloc 403™ by Aquasol (starch), FlexStarch™ by Tate and Lyle, Clear-Cote 640™ by Tate and Lyle (waxystarch), PG270™ by Ingredion (ethylated starch), and a combinationthereof.

In embodiments herein, the binder may include a water-soluble polymerbinder selected from the group including starch binders, cellulosicbinders, polyvinyl alcohol binders, polyacrylic acid binders,polymethacrylic acid binders, polyvinylamine binders, polyacrylamidebinders, polyether binders, sulfonated polystyrene binders, carboxylatedpolystyrene binders, and a combination thereof.

In embodiments herein, the water-soluble polymer binder may be a starchbinder.

In embodiments herein, the binder may include a polymer latex binderselected from the group including styrene butadiene rubber latexes,acrylic polymer latexes, polyvinyl acetate latexes, styrene acryliccopolymer latexes, polyurethane latexes, starch/acrylic copolymerlatexes, starch/styrene acrylic copolymer latexes, polyvinyl alcohol(PVOH)/styrene acrylic copolymer latexes, PVOH/acrylic copolymerlatexes, and a combination thereof.

In embodiments herein, the polymer latex binder may be a styrene-acryliclatex binder.

In embodiments herein, the binder may be ethylated starch.

In embodiments herein, any combination of binder may be suitably used.

In embodiments herein, the pigment may be selected from the groupincluding ground calcium carbonate (GCC), precipitated calcium carbonate(PCC), clay, kaolin clay, talc, mica, calcium sulfate, absorbent plasticpigment particles, calcined clay pigment particles, titanium dioxidepigment particles, barium sulfate pigment particles, silica pigmentparticles, zeolite pigment particles, fumed silica pigment particles,alumina pigment particles, bentonite clay pigment particles, HC(Hydrocarb) 90™ by Omya (ground calcium carbonate), HC (Hydrocarb) 60™by Omya (ground calcium carbonate), Hydrafine 90W™ by KaMin (clay), anda mixture thereof.

In embodiments herein, the pigment may be ground calcium carbonate(GCC).

In embodiments herein, any combination of pigment may be suitably used.

In embodiments herein, the pigment may be finely divided, e.g., having asize range of from about 0.5 to about 5 microns. This range includes allvalues and subranges therebetween, including about 0.5, 0.6, 0.7, 0.8,0.9, 1, 2, 3, 4, and 5 microns.

In embodiments herein, the synthetic surface sizing agent generallyrefers to a non-starch surface sizing agent. The synthetic surfacesizing agent is not particularly limited and may be selected from thegroup including styrene maleic anhydride (SMA), alkyl ketene dimer(AKD), AKD (IP Size 2000)™ by Solenis (alkyl ketene dimer), Scripset745™ by Solenis (styrene maleic anhydride), styrene acrylic emulsion(SAE), polymer emulsions with a surface energy of 50 dynes or less afterdrying, and a combination thereof.

In embodiments herein, the synthetic surface sizing agent may be styrenemaleic anhydride (SMA).

In embodiments herein, the synthetic surface sizing agent may beScripset™.

In embodiments herein, any combination of synthetic surface sizing agentmay be suitably used.

In embodiments herein, the size press composition may further includeone or more water soluble salt.

In embodiments herein, the water soluble salt may be one or more of amultivalent cationic metal salt, an inorganic salt, an organic salt, ora combination thereof.

In embodiments herein, the water soluble salt may be one or moremultivalent cationic metal salt, inorganic salt, organic salt, orcombination thereof selected from the group including calcium chloride,calcium acetate, calcium magnesium acetate, calcium nitrate, calciumhydroxide, magnesium chloride, magnesium sulfate, magnesium nitrate,magnesium sulfate, aluminum chloride, aluminum nitrate, aluminumchlorohydrate, aluminum sulfate, sodium aluminum sulfate, vanadiumchloride, and a combination thereof.

In embodiments herein, the water soluble salt may be calcium chloride.

In embodiments herein, the water soluble salt may be a metal dryingsalt, multivalent metal drying salt, monovalent metal drying salt, or acombination thereof.

In embodiments herein, a metal drying salt may suitably refer to thosemetal salts which may improve the dry time of inks deposited or printedon printable substrates by inkjet printing processes.

In embodiments herein, the multivalent metal drying salt may be selectedfrom the group including calcium chloride, calcium acetate, calciumhydroxide, calcium nitrate, calcium sulfate, calcium sulfite, magnesiumchloride, magnesium acetate, magnesium nitrate, magnesium sulfate,magnesium sulfite, aluminum chloride, aluminum nitrate, aluminumsulfate, aluminum chlorohydrate, sodium aluminum sulfate, vanadiumchloride, and a combination thereof.

In embodiments herein, the monovalent metal drying salt may be selectedfrom the group including sodium chloride, sodium acetate, sodiumcarbonate, sodium bicarbonate, sodium hydroxide, sodium silicates,sodium sulfate, sodium sulfite, sodium nitrate, sodium bromide,potassium chloride, potassium acetate, potassium carbonate, potassiumbicarbonate, potassium hydroxide, potassium silicates, potassiumsulfate, potassium sulfite, potassium nitrate, potassium bromide,lithium chloride, lithium acetate, lithium carbonate, lithiumbicarbonate, lithium hydroxide, lithium silicates, lithium sulfate,lithium sulfite, lithium nitrate, lithium bromide, or a combinationthereof.

In embodiments herein, any combination of salt may be suitably used.

In embodiments herein, in the size press composition, the water solublesalt may be present in an amount of 3 to 30 parts by weight, based onthe weight of the composition. This range includes all values andsubranges therebetween, including 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13,14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, and 30parts by weight, based on the weight of the composition.

In embodiments herein, in the size press composition, the water solublesalt may be present in an amount of 5 to 20 parts by weight, based onthe weight of the composition. This range includes all values andsubranges therebetween, including 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15,16, 17, 18, 19, and 20 parts by weight, based on the weight of thecomposition.

In embodiments herein, in the size press composition, the water solublesalt may be present in an amount such that the metal anion of the watersoluble salt has the same equivalent weight as the calcium anion basedon 3 to 30 parts by weight of calcium chloride, based on the weight ofthe composition. This range includes all values and subrangestherebetween, including 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16,17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, and 30 parts byweight of calcium chloride, based on the weight of the composition.

In embodiments herein, the size press composition may have a % solids ofabout 10-30% solids by weight. This range includes all values andsubranges therebetween, including about 10, 11, 12, 13, 14, 15, 16, 17,18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, and 30% solids byweight, based on the weight of the composition.

In embodiments herein, the size press composition may have a % solids ofabout 20-30% solids by weight.

In embodiments herein, the term “% solids” refers to the percentage ofnon-volatile, non-liquid components (by weight) that are present in thesizing, coating, composition, etc.

In embodiments herein, one example of the size press composition mayinclude starch/GCC (2:1 starch:GCC ratio) with Scripset (SMA) surfacesizing (5 parts Scripset: 100 parts starch/GCC). In embodiments herein,as an example, the size press formulation may be applied with arod-metered size press.

In embodiments herein, one example of starch is ethylated starch, oneexample of pigment is GCC, one example of synthetic surface sizing agentis Scripset SMA, and one example is applying the size press compositionwith a rod-metered size press.

In embodiments herein, the binder and pigment are suitably present in abinder:pigment weight ratio of about 10:1 to about 1:10. This rangeincludes all values and subranges therebetween, including 10, 9, 8, 7,6, 5, 4, 3, 2, or 1:1; 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1:2; 10, 9, 8, 7,6, 5, 4, 3, 2, or 1:3; 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1:4; 10, 9, 8, 7,6, 5, 4, 3, 2, or 1:5; 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1:6; 10, 9, 8, 7,6, 5, 4, 3, 2, or 1:7; 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1:8; 10, 9, 8, 7,6, 5, 4, 3, 2, or 1:9; and 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1:10.

In embodiments herein, in the size press composition, the binder andpigment may be present in a binder:pigment weight ratio of about 4:1 toabout 1:1.

In embodiments herein, the synthetic surface sizing is suitably presentin a synthetic surface sizing agent:(binder and pigment) weight ratio ofabout 2:100 to about 10:100. This range includes all values andsubranges therebetween, including 2, 3, 4, 5, 6, 7, 8, 9, or 10:100.

In embodiments herein, in the size press composition, the syntheticsurface sizing may be present in a synthetic surface sizingagent:(binder and pigment) weight ratio of about 3:100 to about 6:100.

In another embodiment, a sized web for paper or paperboard is provided,which includes:

a dried web including cellulosic fibers; and

the size press composition on one or both sides of the dried web.

In embodiments herein, prior to being contacted with the size presscomposition, the dried web is not coated, i.e., the dried web has a zeroor substantially zero surface loading of a coating or sizing present onone or both sides or surfaces of the web. As used herein, the size presscomposition is considered to be distinct from coatings such as describedin U.S. Pat. No. 9,670,621.

In embodiments herein, the sizing may be present on one side, or on bothsides of the dried web. In embodiments herein, if present on both sidesof the dried web, the sizing may be the same or different on therespective sides.

In embodiments herein, the sizing may include starch, pigment andScripset. In embodiments herein, the sizing may include binders otherthan starch. In embodiments herein, the sizing may include a combinationof starch and non-starch binders. In embodiments herein, the bindersother than starch may have greater “binding strength” than starch and inthat case may be used at lower levels than that of starch and stillresult in coatings that are not “dusty”.

In embodiments herein, other process steps such as drying, coating, andcalendering of the paperboard can be performed after the size presstreatment, as these subsequent processing steps will not be hindered bythese size press treatments, and in some ways can be improved. Forexample, the size press treatment herein can result in a smootherpaperboard, and if desired, can be dried and calendered, resulting in anuncoated (but sized) paperboard with enhanced smoothness andprintability. As another example, the paperboard can be coated after thesize press treatment, so that subsequent coatings will be smoother, andperhaps can be reduced in thickness and still achieve adequate coverage.As another example, by including the proper amount and type of surfacesizing and/or starch cobinders to the size press formulation, holdoutfor subsequent coatings can be improved so that less water and watersoluble binders are absorbed into the paperboard, resulting in strongercoatings and improved barrier properties.

In another embodiment, a coated or uncoated paper or paperboard isprovided, which includes the sized web.

In another embodiment, a paper or paperboard is provided, whichincludes:

a sized web, which includes:

-   -   a dried web including cellulosic fibers; and    -   a size press composition on one or both sides of the dried web,        the size press composition including:        -   binder;        -   pigment;        -   synthetic surface sizing agent; and        -   substantially no water;

wherein the binder and pigment are present in a binder:pigment weightratio of about 10:1 to about 1:10; and

wherein the synthetic surface sizing is present in a synthetic surfacesizing agent:(binder and pigment) weight ratio of about 2:100 to about10:100.

In embodiments herein, the paper or paperboard may be coated oruncoated.

In embodiments herein, the paper or paperboard may include one or morecoatings in contact with one or both sides of the sized web.

In embodiments herein, the coatings, e.g., base coat, top coat, or both,may refer to those compositions which may be applied over the sized web,and do not refer to the size press composition per se. In embodimentsherein, the surface sizing composition may have a lower solids contentthan that of the coatings, and the surface sizing composition maypenetrate into the dried web somewhat, in forming one embodiment of thesized web. The coatings may suitably and independently contain optionaladditives, such as, for example, a metal salt drying agents, cationicdye fixing agents, optical brightening agents, fluorescent whiteningagents, solvents, diluents, anti-scratch and mar resistance agents,defoamers, rheology modifiers, thickeners, lubricants, dispersants,surfactants, or combination thereof. For example, the coating orcoatings may independently contain Alcogum L229™ by Kemira, (styreneacrylic thickener), Berchem 4136™ by Bercen (diglyceride lubricant),Rheocarb 121™ by Coatex, SunKote 455™ by Omnova (calcium stearate),Accumer 9300™ by Dow (acrylic homopolymer), or a combination thereof.The coating compositions may be independently formulated as an aqueoussolution, an aqueous slurry, a colloidal suspension, a liquid mixture, athixotropic mixture, etc.

In embodiments herein, the paper or paperboard may include one or morecoatings on one or both sides of the sized web, such as C1S (coated onone side), C2S (coated on both sides), coated C1S, or coated C2S.

In embodiments herein, the paper or paperboard may include a base coatin contact with one or both sides of the sized web.

In embodiments herein, the paper or paperboard may include a base coatone or both sides of the sized web, such as a C1S or C2S coating incontact with sized web.

In embodiments herein, if coated with a base coat on both sides, thebase coats may be the same or different.

In embodiments herein, the paper or paperboard may include a top coat incontact with the base coat on one or both sides of the sized web.

In embodiments herein, the paper or paperboard may include a top coat,such as a C1S or C2S coating.

In embodiments herein, if coated with a top coat on both sides, the topcoats may be the same or different.

In embodiments herein, a dried web refers to a fibrous web that may beformed, created, produced, etc., on a moving wire of a papermakingmachine from an aqueous mixture, furnish, etc., including at leastcellulosic fibers, and then dried. In embodiments herein, the web may besuitably dried to contain less than or equal to 10% by weight water.This range includes all values and subranges therebetween, including 10,9, 8, 7, 6, 5, 4, 3, 2, 1, 0.5, 0.1% by weight, or less water.

The dried web suitably includes a plurality of cellulosic fibers. Thetype of cellulosic fiber is not critical, and any such fiber known orsuitable for use in paper making can be used. For example, the web canmade from pulp fibers derived from hardwood trees, softwood trees, or acombination of hardwood and softwood trees. The fibers may be preparedfor use in a papermaking furnish by one or more known or suitabledigestion, refining, and/or bleaching operations such as, for example,known mechanical, thermomechanical, chemical and/or semichemical pulpingand/or other well known pulping processes. The term, “hardwood pulps” asmay be used herein include fibrous pulp derived from the woody substanceof deciduous trees (angiosperms) such as birch, oak, beech, maple, andeucalyptus. The Willi, “softwood pulps” as may be used herein includefibrous pulps derived from the woody substance of coniferous trees(gymnosperms) such as varieties of fir, spruce, and pine, as for exampleloblolly pine, slash pine, Colorado spruce, balsam fir and Douglas fir.In some embodiments, at least a portion of the pulp fibers may beprovided from non-woody herbaceous plants including, but not limited to,kenaf, hemp, jute, flax, sisal, or abaca, although legal restrictionsand other considerations may make the utilization of hemp and otherfiber sources impractical or impossible. Either bleached or unbleachedpulp fiber may be utilized. Recycled pulp fibers are also suitable foruse.

In embodiments herein, the dried web may suitably contain from 1 to 99wt % of cellulosic fibers based upon the total weight of the web. In oneembodiment, the dried web may contain from 5 to 95 wt % of cellulosicfibers based upon the total weight of the web. These ranges include anyand all values and subranges therebetween, for example, 1, 5, 10, 15,20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95 and 99 wt%.

In embodiments herein, the dried web may optionally contain from 1 to100 wt % cellulosic fibers originating from softwood species based uponthe total amount of cellulosic fibers in the dried web. In oneembodiment, the dried web may contain 10 to 60 wt % cellulosic fibersoriginating from softwood species based upon the total amount ofcellulosic fibers in the dried web. These ranges include 1, 2, 5, 10,15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, and100 wt % and any and all ranges and subranges therein, based upon thetotal amount of cellulosic fibers in the dried web.

In embodiments herein, the dried web may alternatively or overlappinglycontain from 0.01 to 99 wt % fibers from softwood species, based on thetotal weight of the dried web. In another embodiment, the dried web maycontain from 10 to 60 wt % fibers from softwood species based upon thetotal weight of the dried web. These ranges include any and all valuesand subranges therein. For example, the dried web may contain not morethan 0.01, 0.05, 0.1, 0.2, 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 15,20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95 and 99 wt% softwood based upon the total weight of the dried web.

In embodiments herein, all or part of the softwood fibers may optionallyoriginate from softwood species having a Canadian Standard Freeness(CSF) of from 300 to 750. In one embodiment, the dried web containsfibers from a softwood species having a CSF from 400 to 550. Theseranges include any and all values and subranges therebetween, forexample, 300, 310, 320, 330, 340, 350, 360, 370, 380, 390, 400, 410,420, 430, 440, 450, 460, 470, 480, 490, 500, 510, 520, 530, 540, 550,560, 570, 580, 590, 600, 610, 620, 630, 640, 650, 660, 670, 680, 690,700, 710, 720, 730, 740, and 750 CSF. Canadian Standard Freeness is asmeasured by TAPPI T-227 standard test.

In embodiments herein, the dried web may optionally contain from 1 to100 wt % cellulosic fibers originating from hardwood species based uponthe total amount of cellulosic fibers in the dried web. In oneembodiment, the dried web may contain from 30 to 90 wt % cellulosicfibers originating from hardwood species, based upon the total amount ofcellulosic fibers in the dried web. These ranges include 1, 2, 5, 10,15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, and100 wt %, and any and all values and subranges therein, based upon thetotal amount of cellulosic fibers in the dried web.

In embodiments herein, the dried web may alternatively or overlappinglycontain from 0.01 to 99 wt % fibers from hardwood species, based uponthe total weight of the dried web. In another embodiment, the dried webmay alternatively or overlappingly contain from 60 to 90 wt % fibersfrom hardwood species, based upon the total weight of the dried web.These ranges include any and all values and subranges therebetween,including not more than 0.01, 0.05, 0.1, 0.2, 0.5, 1, 2, 3, 4, 5, 6, 7,8, 9, 10, 12, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80,85, 90, 95, 99 and 99 wt %, based upon the total weight of the driedweb.

In embodiments herein, all or part of the hardwood fibers may optionallyoriginate from hardwood species having a Canadian Standard Freeness offrom 300 to 750. In one embodiment, the dried web may contain fibersfrom hardwood species having CSF values of from 400 to 550. These rangesinclude 300, 310, 320, 330, 340, 350, 360, 370, 380, 390, 400, 410, 420,430, 440, 450, 460, 470, 480, 490, 500, 510, 520, 530, 540, 550, 560,570, 580, 590, 600, 610, 620, 630, 640, 650, 660, 670, 680, 690, 700,710, 720, 730, 740, and 750 CSF, and any and all ranges and subrangestherein.

In embodiments herein, the dried web may optionally contain less refinedfibers, for example, less refined softwood fibers, less refinedhardwood, or both. Combinations of less refined and more refined fibersare possible. In one embodiment, the dried web contains fibers that areat least 2% less refined than that of fibers used in conventional driedwebs. This range includes all values and subranges therebetween,including at least 2, 5, 10, 15, and 20%.

When the dried web contains both hardwood fibers and softwood fibers,the hardwood/softwood fiber weight ratio may optionally range from 0.001to 1000. In one embodiment, the hardwood/softwood ratio may range from90/10 to 30/60. These ranges include all values and subrangestherebetween, including 0.001, 0.002, 0.005, 0.01, 0.02, 0.05, 0.1, 0.2,0.5, 1, 2, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75,80, 85, 90, 95, 100, 200, 300, 400, 500, 600, 700, 800, 900, and 1000.

In embodiments herein, the softwood fibers, hardwood fibers, or both maybe optionally modified by physical and/or chemical processes. Examplesof physical processes include, but are not limited to, electromagneticand mechanical processes. Examples of electrical modifications include,but are not limited to, processes involving contacting the fibers withan electromagnetic energy source such as light and/or electricalcurrent. Examples of mechanical modifications include, but are notlimited to, processes involving contacting an inanimate object with thefibers. Examples of such inanimate objects include those with sharpand/or dull edges. Such processes also involve, for example, cutting,kneading, pounding, impaling, and the like, and combinations thereof.

Non-limiting examples of chemical modifications include conventionalchemical fiber processes such as crosslinking and/or precipitation ofcomplexes thereon. Other examples of suitable modifications of fibersinclude those found in U.S. Pat. Nos. 6,592,717, 6,592,712, 6,582,557,6,579,415, 6,579,414, 6,506,282, 6,471,824, 6,361,651, 6,146,494,H1,704, 5,731,080, 5,698,688, 5,698,074, 5,667,637, 5,662,773,5,531,728, 5,443,899, 5,360,420, 5,266,250, 5,209,953, 5,160,789,5,049,235, 4,986,882, 4,496,427, 4,431,481, 4,174,417, 4,166,894,4,075,136, and 4,022,965, the entire contents of each of which arehereby incorporated, independently, by reference. Still other examplesof suitable modifications of fibers may be found in U.S. ApplicationNos. 60/654,712, filed Feb. 19, 2005, and Ser. No. 11/358,543, filedFeb. 21, 2006, which may include the addition of optical brighteners(i.e. OBAs) as discussed therein, the entire contents of each of whichare hereby incorporated, independently, by reference.

In embodiments herein, the dried web may optionally include “fines.”“Fines” fibers are typically those fibers with average lengths of notmore than about 100 μm. Sources of “fines” may be found in SaveAllfibers, recirculated streams, reject streams, waste fiber streams, andcombinations thereof. The amount of “fines” present in the dried web canbe modified, for example, by tailoring the rate at which streams areadded to the paper making process. In one embodiment, the averagelengths of the fines are not more than about 5, 10, 15, 20, 25, 30, 35,40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, and 100 μm, includingany and all ranges and subranges therein.

If used, the “fines” fibers may be present in the dried web togetherwith hardwood fibers, softwood fibers, or both hardwood and softwoodfibers.

In embodiments herein, the dried web may optionally contain from 0.01 to100 wt % fines, based on the total weight of the dried web. In oneembodiment, the dried web may contain from 0.01 to 50 wt % fines, basedupon the total weight of the web. These ranges include all values andsubranges therebetween, including not more than 0.01, 0.05, 0.1, 0.2,0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 15, 20, 25, 30, 35, 40, 45, 50,55, 60, 65, 70, 75, 80, 85, 90, 95 and 100 wt % fines, based upon thetotal weight of the dried web.

In embodiments herein, the dried web may alternatively or overlappinglycontain from 0.01 to 100 wt % fines, based upon the total weight of thefibers in the dried web. This range includes all values and subrangestherebetween, including not more than 0.01, 0.05, 0.1, 0.2, 0.5, 1, 2,3, 4, 5, 6, 7, 8, 9, 10, 12, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65,70, 75, 80, 85, 90, 95 and 100 wt % fines, based upon the total weightof the fibers in by the dried web.

In embodiments herein, the paper or paperboard may have a basis weightof from about 8 pt to about 30 pt. This range includes all values andsubranges therebetween, including about 8, 9, 10, 11, 12, 13, 14, 15,16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, and 30 pt.

In embodiments herein, the paper or paperboard may have a basis weightof from about 10 pt to about 24 pt.

In another embodiment, an article is provided, which includes the paperor paperboard.

In embodiments herein, the article may be suitable for one or more ofinkjet, flexo, gravure, or offset printing, or a combination of two ormore thereof.

In embodiments herein, article may be selected from the group includingpackaging, food service item, cup, plate, and a combination thereof. Inembodiments herein, the paper or paperboard is in the form of cupstockor platestock.

In embodiments herein, the sized web, paper or paperboard, or articlemay have improved barrier properties, improved water barrier properties,improved oil barrier properties, improved barrier layer for OGWRcoating, improved water barrier for cup and/or platestock, improved(lower) dust properties, improved smoothness for flexo, gravure, andoffset printing, or a combination thereof.

In another embodiment, a method is provided, which includes contacting,on a papermaking machine:

a dried web including cellulosic fibers; and

the size press composition;

to form a sized web.

In embodiments herein, contacting the dried web and the size presscomposition may be carried out at a size press selected from the groupincluding rod-metered size press, puddle size press, blade-metered sizepress, curtain coater size press, vertical size press, horizontal sizepress, metering size press, gated roll metering size press, doctor blademetering size press, and a combination thereof.

In embodiments herein, contacting the dried web and the size presscomposition may be carried out carried out at a rod-metered size press.

In embodiments herein, the base coat may be applied to one or both sidesof the sized web, to form a coated paper or paperboard.

In embodiments herein, the base coat formulation may include a standardpigment containing coating designed for flexo and offset printing. Forexample, the base coat may include 10 to 20 parts latex binder and 100parts pigment; a barrier coating containing a higher proportion ofbinder; or a specialty coating containing only latex. The binder is notparticularly limiting. Non-limiting examples of the binder include RAP810™ by Trinseo (styrene acrylate), XU 31669 SB™ latex by Trinseo(styrene butadiene), XU 31695™ by Trinseo (styrene acrylonitrile),Polyco 3960™ by Dow (poly vinyl acetate), Polyco 2160 IPA™ by Dow (polyvinyl acetate), Hypod 1001™ by Dow (polyethylene emulsion), Hypod 9105™by Dow (polyethylene emulsion), or a combination thereof. Similarly, thepigment is not particularly limiting. Non-limiting examples of pigmentinclude HC (Hydrocarb) 90™ by Omya (ground calcium carbonate), HC(Hydrocarb) 60™ by Omya (ground calcium carbonate), Hydrafine 90W™ byKaMin (clay), and combinations thereof. In some embodiments, the pigmentis HC (Hydrocarb) 60™ by Omya (ground calcium carbonate).

In embodiments herein, the pigment in the base coat formulation mayinclude one or more of clay and calcium carbonate.

In embodiments herein, the term, “top” is used merely for convenienceand is not intended to imply a particular direction.

In embodiments herein, a top coat may be applied to the base coat on oneor both sides of the sized web, to form a coated paper or paperboard.

In embodiments herein, the top coat formulation may include a standardpigment containing coating designed for flexo and offset printing. Forexample, the top coat formulation may include 10 to 20 parts latexbinder and 100 parts pigment; a barrier coating containing a higherproportion of binder; or a specialty coating containing only latex. Thebinder is not particularly limiting. Non-limiting examples of the binderinclude RAP 810™ by Trinseo (styrene acrylate), XU 31669 SB™ latex byTrinseo (styrene butadiene), XU 31695™ by Trinseo (styreneacrylonitrile), Polyco 3960™ by Dow (poly vinyl acetate), Polyco 2160IPA™ by Dow (poly vinyl acetate), Hypod 1001™ by Dow (polyethyleneemulsion), Hypod 9105™ by Dow (polyethylene emulsion), or a combinationthereof. Similarly, the pigment is not particularly limiting.Non-limiting examples of pigment include HC (Hydrocarb) 90™ by Omya(ground calcium carbonate), HC (Hydrocarb) 60™ by Omya (ground calciumcarbonate), Hydrafine 90W™ by KaMin (clay), and combinations thereof. Insome embodiments, the pigment is HC (Hydrocarb) 90™ by Omya (groundcalcium carbonate), Hydrafine 90W™ by KaMin (clay), or a combinationthereof.

In embodiments herein, the pigment in the top coat formulation mayinclude one or more of clay and calcium carbonate.

In embodiments herein, one or more of drying, coating, or calendaringthe sized web, or a combination of two or more thereof may be furthercarried out.

EXAMPLES

The examples herein are provided for illustration only and are notintended to be limiting unless otherwise specified.

Example 1

Coated paper substrates were made on the Trinseo pilot coater inMidland, Mich. (Table 1). The base paperboard was a 14 point uncoatedcupstock having no size press treatment. Surface size compositions (asshown in Table 1 below) were applied to both sides of this uncoatedcupstock at the rate of 1300 feet per minute (fpm) using a rod meteredsize press and dried using an infrared (IR) dryer, followed by a forcedair oven. Comparative Samples S-1 and S-2 had a control surface sizecomposition applied, consisting of a 6% solids solution of PG-270ethylated corn starch, which is a size press formulation that is similarto many commercial paperboards currently available. Exemplary SamplesS-3 and S-4 had a pigmented size press composition applied in accordancewith an embodiment of the present invention. Subsequently, all foursamples were coated on one side of the paperboard with a base coat andthen a top coat. The base coats were applied using a blade coater in thestiff blade mode, while the top coats were applied using a blade coaterin the bent blade mode. Both coatings were dried after coating using aninfrared (IR) dryer, followed by a forced air oven. The coatingformulations for the base coats and the top coats are listed in Table 1.

The components, layers, and properties of these coated paper substratesare shown in Table 1 below:

TABLE 1 Comp Comp Sample Sample Sample Sample S-1 S-2 S-3 S-4 PaperSubstrate Caliper (points) 14  14  14 14 Basis Weight¹ 165  165  165 165  Size Press Composition² Starch binder³ 100  100  66 66 Pigment⁴ 0 033 33 Synthetic Surface Sizing 0 0 10 10 Agent⁵ Salt⁶ 0 0  1  1 % solids6 6 25 25 Pick-up¹ 2 2  6  6 Base Coat Pigment⁷ 100  100  100  100 Latex Binder 14⁸  13⁹   14⁸  13⁹ Dispersant¹⁰   0.18   0.18    0.18   0.18 Dispersant¹¹   0.3   0.3   0.3   0.3 Thickener¹²   0.2   0.2  0.2   0.2 Coat Weight¹ 8 8  7  7 Top Coat Pigment, GCC⁴ 70  70  70 70Pigment, Clay¹³ 30  30  30 30 Latex Binder   14.5⁸   13.5⁹   14.5⁸  13.5⁹ Dispersant¹⁰   0.19   0.19    0.19    0.19 Dispersant¹¹   0.1  0.1   0.1   0.1 Thickener¹²   0.3   0.3   0.3   0.3 Lubricant¹⁴ 1 1  1Coat Weight¹ 7 8  8  8 Test Results Hagerty Permeability 232  157  886 556  (sec per 10 cc) Parker Print Surf   1.88   1.94    1.52    1.53Flexo Print Mottle  15.5  11.1   6.6   7.4 ¹In lbs/3 msf ²Amounts(estimated) in dry parts ³From Ingredion, PG 270 ethylated corn starch⁴From Omya, Hydrocarb 90 GCC ⁵From Solenis, Scripset 745 SMA ⁶FromAldrich, Calcium Chloride ⁷From Omya, Hydrocarb 60 GCC ⁸From Trinseo,XU31695, which is a styrene-acrylic-acrylonitrile copolymer latex ⁹FromTrinseo, RAP830, which is a styrene-acrylic copolymer latex. ¹⁰From Dow,Accumer 9300 ¹¹From Omya, Rheocarb 121 ¹²From Kemira, FennoFlow L229¹³From KaMin, Hydrafine 90W clay ¹⁴From Omnova, SunKote 455 calciumstearate

The four coated paperboard samples were then tested for HagertyPermeability and Parker Print Surf. Hagerty Permeability is a measure ofthe porosity of the coated paperboard, measuring the time in seconds fora 10 cubic centimeter volume of air to pass through the sample at afixed pressure. The higher the number, the longer time it takes the airto pass through the coated paperboard, and hence the less porous thepaperboard. Parker Print Surf is a measure of the surface roughness overa small area of the sample surface. The higher the number, the rougherthe sample. Samples were also tested for flexo print mottle evaluation.The higher the number, the more mottle can be detected on the printedpaperboard sample. The results of these tests are listed in Table 1.

From the coating compositions listed in Table 1, it should be noted thatSamples S-1 and S-3 have the same base coat and top coat coatingcompositions, but differ in that Comparative Sample S-1 has a size presscomposition consisting of starch only, and Exemplary Sample S-3 has asize press formulation in accordance with an embodiment of the presentinvention. The results in Table 1 show that Exemplary Sample S-3 has ahigher Hagerty Permeability value than Comparative Sample S-1, whichindicates that Exemplary Sample S-3 is less porous than ComparativeSample S-1. Exemplary Sample S-3 also has a significantly smoothersurface than Comparative Sample S-1, as indicated by the lower value forParker Print Surf, as well as the lower flexo print mottle. Theseobservations also hold true for Samples S-2 (Comparative) and S-4(Exemplary), which have the same coating formulations but different sizepress compositions. The coating formulations between S-1 and S-3 and S-2and S-4 differ only in the latex binder used.

Example 2

Coated paper substrates were made on the Trinseo pilot coater inMidland, Mich. (Table 2). The base paperboard was a 14 point uncoatedcupstock having no size press treatment. Surface size compositions (asshown in Table 2 below) were applied to both sides of this uncoatedcupstock at the rate of 1300 feet per minute (fpm) using a rod meteredsize press and dried using an infrared (IR) dryer, followed by a forcedair oven. Comparative Samples S-5 and S-9 had a control surface sizecomposition applied, consisting of a 6% solids solution of PG-270ethylated corn starch, which is a size press formulation that is similarto many commercial paperboards currently available. Exemplary SamplesS-6, S-7, S-8, S-10, S-11, and S-12 had a pigmented size presscomposition applied in accordance with an embodiment of the presentinvention. Subsequently, all eight samples were coated on one side ofthe paperboard with a base coat and then a top coat. The base coats wereapplied using a blade coater in the stiff blade mode, while the topcoats were applied using a blade coater in the bent blade mode. Bothcoatings were dried after coating using an infrared (IR) dryer, followedby a forced air oven. The coating formulations for the base coats andthe top coats are listed in Table 2.

The components, layers, and properties of these coated paper substratesare shown in Table 2 below:

TABLE 2 Comp Comp Sample Sample Sample Sample Sample Sample SampleSample S-5 S-6 S-7 S-8 S-9 S-10 S-11 S-12 Paper Substrate Caliper(points) 14 14 14 14 14 14 14 14 Basis Weight¹ 165  165  165  165  165 165  165  165  Size Press Composition² Starch binder 100³    66³  66⁴ 66⁴ 100³    66³  66⁴  66⁴ Pigment⁵  0 33 33 33  0 33 33 33 Synthetic  0  5⁶   5⁶  10⁷  0   5⁶   5⁶  10⁷ Surface Sizing Agent % solids  6 25 2525  6 25 25 25 Pick-up¹  2  5  5  4  2  5  5  4 Base Coat Pigment, GCC⁸60 60 60 60 60 60 60 60 Pigment, Clay⁵ 40 40 40 40 40 40 40 40 LatexBinder  20⁹  20⁹  20⁹  20⁹  20¹⁰  20¹⁰  20¹⁰  20¹⁰ Dispersant¹¹    0.18   0.18    0.18    0.18    0.18    0.18    0.18    0.18 Thickener¹²  0.2   0.2   0.2   0.2   0.2   0.2   0.2   0.2 Coat Weight¹  7  6  6  5 7  7  7  7 Top Coat Pigment, GCC¹³ 60 60 60 60 60 60 60 60 Pigment,Clay⁵ 40 40 40 40 40 40 40 40 Latex Binder¹⁰ 18 18 18 18 18 18 18 18Dispersant¹¹    0.19    0.19    0.19    0.19    0.19    0.19    0.19   0.19 Thickener¹²    0.05    0.05    0.05    0.05    0.05    0.05   0.05    0.05 Lubricant¹⁴  1  1  1  1  1  1  1  1 Coat Weight¹  8  7 8  7  8  8  8  8 Test Results Hagerty 921  1606  1586  1522  604  1180 1390  1252  Permeability (sec per 10 cc) Hot Corn Oil   26.5   19.8  13.3   13.6   27.2   20.1   16.5   18.5 Test ¹In lbs/3 msf ²Amounts(estimated) in dry parts ³From Ingredion, PG 270, ethylated corn starch⁴From Ingredion, FilmCote 370, corn starch ⁵From KaMin, Hydrafine 90W,clay ⁶From Solenis, IP Size 2000, AKD ⁷From Solenis, Scripset 745, SMA⁸From Omya, Hydrocarb 60 GCC ⁹From Trinseo, XU31669, styrene-butadienecopolymer latex ¹⁰From Trinseo, RAP810, styrene-acrylic copolymer latex.¹¹From Dow, Accumer 9300 ¹²From Kemira, FennoFlow L229 ¹³From Omya,Hydrocarb 90, GCC ¹⁴From Berchem, Berchem 4136

The eight coated paperboard samples were then tested for HagertyPermeability and Hot Corn Oil holdout. Hagerty Permeability is a measureof the porosity of the coated paperboard, measuring the time in secondsfor a 10 cubic centimeter volume of air to pass through the sample at afixed pressure. The higher the number, the longer time it takes the airto pass through the coated paperboard, and hence the less porous thepaperboard. The Hot Corn Oil test is conducted by placing a measuredamount of corn oil at 60° C. onto the paperboard sample. Once the paperhas cooled down to room temperature, the excess corn oil is removed, andthe oil-containing paperboard is left at room temperature for 24 hours.The Y-value brightness of the paperboard is then measured, and thechange in Y-value brightness before and after the test is reported. Thehigher number, the more corn oil was absorbed by the paperboard sample.

The aforementioned Hot Corn Oil test is described in more detail in thepatent application WO2009142739A1 in relevant part as follows: Placesamples of the coated base paper (8.3 cm by 8.3 cm) with the coated sidedown and against a Leneta Scrub Chart. Make an initial Y-value readingof the coated base paper from the middle of the sample using aspectrophotometer. Then, secure the samples of the coated base paper toa sheet of clean Plexiglas® with the coated side up. Use a circletemplate to draw a 5.08 cm diameter circle around the middle of thecoated base paper samples. Use a hot glue gun to deposit a bead of gluealong the circle to create a “glue dam.” Allow the glue dam to cool andharden for a minimum of 15 minutes at room temperature. Remove 60° C.pre-heated corn oil from an oven set at 60° C. Apply one (1) ml of thehot corn oil to the coated base paper in the area defined by the gluedam. The oil will spread to cover the circle. Place the oil-coveredsamples of the coated base papers into the oven set at 60° C. After ascheduled time interval, remove the samples of the coated base papersfrom the oven and placed on a lab bench to cool to room temperature.Once the samples are at room temperature, wipe the excess oil off thesurface of the samples of the coated base paper. Remove the samples ofthe coated base paper from the Plexiglas® and place with the surfacetreated with the corn oil (oil-stain side) down on a plain black LenetaChart. Read the Y-value of the middle of the square using thespectrophotometer. The results of these tests are listed in Table 2.

From the coating compositions listed in Table 2, it should be noted thatsamples S-5 through S-8 have the same base coat and top coat coatingcompositions, but differ in that Comparative sample S-5 has a size presscomposition consisting of starch only, and Exemplary samples S-6 throughS-8 have a size press formulation in accordance with an embodiment ofthe present invention. The results in Table 2 show that Exemplarysamples S-6 through S-8 have a higher Hagerty Permeability value thanComparative sample S-5, which indicates that Exemplary samples S-6through S-8 are less porous than Comparative sample S-5. ExemplarySamples S-6 through S-8 also have a better oil holdout (less hot cornoil absorbed) than Comparative sample S-5. This is confirmation of thelower porosity of Exemplary samples S-6 through S-8, as seen in theHagerty Permeability test. These observations also hold true for SamplesS-9 through S-12, which have the same coating formulations but differentsize press compositions. The coating formulations between sample S-5through S-8 and samples S-9 through S-12 differ only in the latex binderused in the base coat.

All documents, patents, journal articles and other materials cited inthe present application are hereby incorporated by reference, the sameas if set forth at length.

Although the present invention has been fully described in conjunctionwith several embodiments thereof with reference to the accompanyingdrawings, it is to be understood that various changes and modificationsmay be apparent to those skilled in the art. Such changes andmodifications are to be understood as included within the scope of thepresent invention as defined by the appended claims, unless they departtherefrom.

1. A size press composition for paper or paperboard, comprising: binder;pigment; synthetic surface sizing agent; and water; wherein the binderand pigment are present in a binder:pigment weight ratio of about 10:1to about 1:10; and wherein the synthetic surface sizing is present in asynthetic surface sizing agent:(binder and pigment) weight ratio ofabout 2:100 to about 10:100.
 2. The size press composition of claim 1,wherein the binder comprises one or more of natural product, casein, soyprotein, fatty acid salts and copolymers, water soluble polymer, watersoluble starch co-binder, polyvinyl alcohol, poly acrylic acid, polyacrylic acid salt, polyvinylpyrrolidone, polyethylene glycol,polyethylene oxide, polymer emulsion, acrylate, styrene acrylate,styrene butadiene, styrene acrylonitrile, polyurethane, polyvinylacetate, polyethylene emulsion, polyethylene (PE) polymers; polyethyleneterephthalate (PET) polymers; polyhydroxyalkanoate (PHA) polymers;polylactic acid (PLA) polymers; polyglycolic acid (PGA) polymers;polyvinyl acetate polymers; waxes; polyurethane polymers; or epoxyresins, starch, high-amylose corn starch, waxy corn starch, tapiocastarch, cationic starch, ethylated starch, oxidized starch, corn starch,potato starch, rice starch, dent corn starch, waxy starch, modifiedstarch, FilmKote™ by Ingredion, FilmKote 370™ by Ingredion (modifiedstarch), Aquabloc™ by Aquasol, Aquabloc 403™ by Aquasol (starch), FlexStarch™ by Tate and Lyle, Clear-Cote 640™ by Tate and Lyle (waxystarch), PG270™ by Ingredion (ethylated starch), RAP 810™ by Trinseo(styrene acrylate), XU 31669 SB™ latex by Trinseo (styrene butadiene),XU 31695™ by Trinseo (styrene acrylonitrile), Polyco 3960™ by Dow (polyvinyl acetate), Polyco 2160 IPA™ by Dow (poly vinyl acetate), binder,Hypod 1001™ by Dow (polyethylene emulsion), Hypod 9105™ by Dow(polyethylene emulsion), or a combination thereof.
 3. The size presscomposition of claim 1, wherein the binder comprises one or more naturalproducts such as casein, soy protein, and fatty acid salts andcopolymers, water soluble polymers such as polyvinyl alcohol, polyacrylic acid and salts, polyvinylpyrrolidone, polyethylene glycol,polyethylene oxide, etc, and polymer emulsions such as acrylates,styrene acrylates, styrene butadienes, polyurethanes, polyvinylacetates, polyethylene (PE) polymers; polyethylene terephthalate (PET)polymers; polyhydroxyalkanoate (PHA) polymers; polylactic acid (PLA)polymers; polyglycolic acid (PGA) polymers; polyvinyl acetate polymers;waxes; polyurethane polymers; or epoxy resins, and their copolymers andderivatives.
 4. The size press composition of claim 1, wherein thebinder comprises a starch selected from the group consisting ofhigh-amylose corn starch, waxy corn starch, tapioca starch, cationicstarch, ethylated starch, oxidized starch, corn starch, potato starch,rice starch, dent corn starch, waxy starch, modified starch, FilmKote™by Ingredion, FilmKote 370™ by Ingredion (modified starch), Aquabloc™ byAquasol, Aquabloc 403™ by Aquasol (starch), Flex Starch™ by Tate andLyle, Clear-Cote 640™ by Tate and Lyle (waxy starch), PG270™ byIngredion (ethylated starch), and a combination thereof.
 5. The sizepress composition of claim 1, wherein the binder comprises awater-soluble polymer binder selected from the group consisting ofstarch binders, cellulosic binders, polyvinyl alcohol binders,polyacrylic acid binders, polymethacrylic acid binders, polyvinylaminebinders, polyacrylamide binders, polyether binders, sulfonatedpolystyrene binders, carboxylated polystyrene binders, and a combinationthereof.
 6. The size press composition of claim 5, wherein thewater-soluble polymer binder is a starch binder.
 7. The size presscomposition of claim 1, wherein the binder comprises a polymer latexbinder selected from the group consisting of styrene butadiene rubberlatexes, acrylic polymer latexes, polyvinyl acetate latexes, styreneacrylic copolymer latexes, polyurethane latexes, starch/acryliccopolymer latexes, starch/styrene acrylic copolymer latexes, polyvinylalcohol (PVOH)/styrene acrylic copolymer latexes, PVOH/acrylic copolymerlatexes, and a combination thereof.
 8. The size press composition ofclaim 7, wherein the polymer latex binder is a styrene-acrylic latexbinder.
 9. The size press composition of claim 1, wherein the binder isethylated starch.
 10. The size press composition of claim 1, wherein thepigment is selected from the group consisting of ground calciumcarbonate (GCC), precipitated calcium carbonate (PCC), clay, kaolinclay, talc, mica, calcium sulfate, absorbent plastic pigment particles,calcined clay pigment particles, titanium dioxide pigment particles,barium sulfate pigment particles, silica pigment particles, zeolitepigment particles, fumed silica pigment particles, alumina pigmentparticles, bentonite clay pigment particles, HC (Hydrocarb) 90™ by Omya(ground calcium carbonate), HC (Hydrocarb) 60™ by Omya (ground calciumcarbonate), Hydrafine 90W™ by KaMin (clay), and a mixture thereof. 11.The size press composition of claim 1, wherein the pigment is groundcalcium carbonate (GCC).
 12. The size press composition of claim 1,wherein the synthetic surface sizing agent is selected from the groupconsisting of styrene maleic anhydride (SMA), alkyl ketene dimer (AKD),AKD (IP Size 2000)™ by Solenis (alkyl ketene dimer), Scripset 745™ bySolenis (styrene maleic anhydride), styrene acrylic emulsion (SAE),polymer emulsions with a surface energy of 50 dynes or less afterdrying, and a combination thereof.
 13. The size press composition ofclaim 1, wherein the synthetic surface sizing agent is styrene maleicanhydride (SMA).
 14. The size press composition of claim 1, wherein thesynthetic surface sizing agent is Scripset™.
 15. The size presscomposition of claim 1, further comprising one or more water solublesalt.
 16. The size press composition of claim 15, wherein the watersoluble salt is one or more of a multivalent cationic metal salt, aninorganic salt, an organic salt, or a combination thereof.
 17. The sizepress composition of claim 15, wherein the water soluble salt is one ormore multivalent cationic metal salt, inorganic salt, organic salt, orcombination thereof selected from the group consisting of calciumchloride, calcium acetate, calcium magnesium acetate, calcium nitrate,calcium hydroxide, magnesium chloride, magnesium sulfate, magnesiumnitrate, magnesium sulfate, aluminum chloride, aluminum nitrate,aluminum chlorohydrate, aluminum sulfate, sodium aluminum sulfate,vanadium chloride, and a combination thereof.
 18. The size presscomposition of claim 15, wherein the water soluble salt is calciumchloride.
 19. The size press composition of claim 15, wherein the watersoluble salt is a metal drying salt, multivalent metal drying salt,monovalent metal drying salt, or a combination thereof.
 20. The sizepress composition of claim 19, wherein the multivalent metal drying saltis selected from the group consisting of calcium chloride, calciumacetate, calcium hydroxide, calcium nitrate, calcium sulfate, calciumsulfite, magnesium chloride, magnesium acetate, magnesium nitrate,magnesium sulfate, magnesium sulfite, aluminum chloride, aluminumnitrate, aluminum sulfate, aluminum chlorohydrate, sodium aluminumsulfate, vanadium chloride, and a combination thereof.
 21. The sizepress composition of claim 19, wherein the monovalent metal drying saltis selected from the group consisting of sodium chloride, sodiumacetate, sodium carbonate, sodium bicarbonate, sodium hydroxide, sodiumsilicates, sodium sulfate, sodium sulfite, sodium nitrate, sodiumbromide, potassium chloride, potassium acetate, potassium carbonate,potassium bicarbonate, potassium hydroxide, potassium silicates,potassium sulfate, potassium sulfite, potassium nitrate, potassiumbromide, lithium chloride, lithium acetate, lithium carbonate, lithiumbicarbonate, lithium hydroxide, lithium silicates, lithium sulfate,lithium sulfite, lithium nitrate, lithium bromide, or a combinationthereof.
 22. The size press composition of claim 15, wherein the watersoluble salt is present in an amount of 3 to 30 parts by weight, basedon the weight of the composition.
 23. The size press composition ofclaim 15, wherein the water soluble salt is present in an amount of 5 to20 parts by weight, based on the weight of the composition.
 24. The sizepress composition of claim 15, wherein the water soluble salt is presentin an amount such that the metal anion of the water soluble salt has thesame equivalent weight as the calcium anion based on 3 to 30 parts byweight of calcium chloride, based on the weight of the composition. 25.The size press composition of claim 1, which further comprises a %solids of about 10-30% solids by weight.
 26. The size press compositionof claim 1, which further comprises a % solids of about 20-30% solids byweight.
 27. The size press composition of claim 1, wherein the binderand pigment are present in a binder:pigment weight ratio of about 4:1 toabout 1:1.
 28. The size press composition of claim 1, wherein thesynthetic surface sizing is present in a synthetic surface sizingagent:(binder and pigment) weight ratio of about 3:100 to about 6:100.29. A sized web, for paper or paperboard, comprising: a dried webcomprising cellulosic fibers; and the size press composition of claim 1on one or both sides of the dried web.
 30. A coated or uncoated paper orpaperboard, comprising the sized web of claim
 29. 31. A paper orpaperboard, comprising: a sized web, comprising: a dried web comprisingcellulosic fibers; and a size press composition on one or both sides ofthe dried web, the size press composition comprising: binder; pigment;synthetic surface sizing agent; and substantially no water; wherein thebinder and pigment are present in a binder:pigment weight ratio of about10:1 to about 1:10; and wherein the synthetic surface sizing is presentin a synthetic surface sizing agent:(binder and pigment) weight ratio ofabout 2:100 to about 10:100.
 32. The paper or paperboard of claim 31,which is uncoated.
 33. The paper or paperboard of claim 31, furthercomprising one or more coatings in contact with one or both sides of thesized web.
 34. The paper or paperboard of claim 33, wherein the one ormore coatings are C1S (coated on one side), C2S (coated on both sides),coated C1S, or coated C2S.
 35. The paper or paperboard of claim 31,further comprising a base coat in contact with one or both sides of thesized web.
 36. The paper or paperboard of claim 35, wherein the basecoat is a C1S or C2S coating in contact with sized web.
 37. The paper orpaperboard of claim 35, further comprising a top coat in contact withthe base coat on one or both sides of the sized web.
 38. The paper orpaperboard of claim 37, wherein the top coat is a C1S or C2S coating.39. The paper or paperboard of claim 31, having a basis weight of fromabout 8 pt to about 30 pt.
 40. The paper or paperboard of claim 31,having a basis weight of from about 10 pt to about 24 pt.
 41. Anarticle, comprising the paper or paperboard of claim
 31. 42. The articleof claim 41, which is suitable for one or more of inkjet, flexo,gravure, or offset printing, or a combination of two or more thereof.43. The article of claim 41, which is selected from the group consistingof packaging, food service item, cup, plate, and a combination thereof.44. The article of claim 41, which has improved barrier properties,improved smoothness for flexo, gravure, and offset printing, or acombination thereof.
 45. A method, comprising contacting, on apapermaking machine: a dried web comprising cellulosic fibers; and thesize press composition of claim 1; to form a sized web.
 46. The methodof claim 45, wherein the contacting is carried out at a size pressselected from the group consisting of rod-metered size press, puddlesize press, blade-metered size press, curtain coater size press,vertical size press, horizontal size press, metering size press, gatedroll metering size press, doctor blade metering size press, and acombination thereof.
 47. The method of claim 45, wherein the contactingis carried out at a rod-metered size press.
 48. The method of claim 45,further comprising applying a base coat to one or both sides of thesized web, to form a coated paper or paperboard.
 49. The method of claim48, wherein the base coat is applied from a base coat formulationcomprising a standard pigment containing coating designed for flexo andoffset printing, comprised of 10 to 20 parts latex binder and 100 partspigment; a barrier coating containing a higher proportion of binder; ora specialty coating containing only latex.
 50. The method of claim 49,wherein the pigment comprises one or more of clay and calcium carbonate.51. The method of claim 48, further comprising applying a top coat tothe base coat on one or both sides of the sized web, to form a coatedpaper or paperboard.
 52. The method of claim 51, wherein the top coat isapplied from a top coat formulation comprising a standard pigmentcontaining coating designed for flexo and offset printing, comprised of10 to 20 parts latex binder and 100 parts pigment; a barrier coatingcontaining a higher proportion of binder; or a specialty coatingcontaining only latex.
 53. The method of claim 52, wherein the pigmentcomprises one or more of clay and calcium carbonate.
 54. The method ofclaim 45, further comprising one or more of drying, coating, orcalendaring the sized web, or a combination of two or more thereof.